Segmented Stator Winding Layout to Prevent Wire Tangling
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Solution Overview
Problem
The intricate tangling and deformation of coil-to-coil connecting wires and terminal wires in brushless motors lead to increased production costs and complexity, making automation difficult and requiring special tools or facilities.
Innovation Solution
A stator design with a core composed of multiple segments and coils arranged in a concentrated winding form, using m-series-connected-coil and n-parallel-connected-coil delta configurations, along with power input wires and coil-to-coil connecting wires, allows for simplified connection to a circuit substrate without complex bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the core is shaped into an annular form after wires are wound around the teeth, then the space factor of the winding is increased, but the coil-to-coil connecting wires and terminal wires become intricately tangled, causing deformation or loosening of coils and wires
Solution Approach 1:
The core is divided into multiple core segments that are assembled together to form the annular core. This segmentation allows the winding to be completed on the segmented core structure, preventing wire tangling that would occur if the entire annular core were formed first. The segmented approach enables systematic wire routing and connection without intricate tangling.
Solution Approach 2:
The winding is performed on the segmented core structure before the core segments are fully assembled into the final annular form. This preliminary winding action allows for proper wire routing and connection establishment without the constraints of the final annular configuration, thereby preventing wire tangling and deformation.
2Manufacturing precision
If special tools or facilities are used to prevent wire tangling, then the coil and wire integrity is maintained, but the production cost increases
Solution Approach 1:
By segmenting the core structure, the patent enables a simplified manufacturing process that does not require complex special tools or facilities. The segmented core allows for systematic wire routing and connection using standard manufacturing equipment, thereby maintaining coil and wire integrity while reducing production costs.
3Ease of manufacture
If bus bars are used to connect terminal wires to the circuit substrate, then the shaping of terminal wires is facilitated, but the structure becomes complicated and production cost increases
Solution Approach 1:
The patent eliminates the need for bus bars by directly connecting terminal wires to the circuit substrate through the segmented core structure. This extraction of the bus bar component simplifies the overall structure, reduces the number of parts, and maintains ease of terminal wire shaping while reducing production cost.
4Quantity of substance
If the core is shaped into an annular form after winding, then the space factor is increased, but automation of the process becomes difficult
Solution Approach 1:
The segmented core structure enables automation by allowing standardized, repeatable assembly operations. The segments can be manufactured and prepared separately, then systematically assembled with the winding already in place. This modular approach is readily automatable compared to forming a complete annular core after winding.
Solution Approach 2:
By performing the winding operation on the segmented core structure before final assembly, the patent creates a state that is more amenable to automated processing. The preliminary winding allows for programmed, systematic wire routing and connection that can be easily automated, whereas forming the annular core first would require complex, non-automatable manual operations.
Data Source
AI summary
A core includes a plurality of core segments each of which has a tooth around which wire is wounded in the form of a coil. The core segments are designed to have the coils in a concentrated winding form and also in a m-series-connected-coil and n-parallel-connected-coil delta configuration where m is a natural number more than or equal to two, and n is a natural number or in a k-series-connected-coil and n-parallel-connected-coil delta configuration where k is an even number, and n is a natural number. The coils include U-phase coils working for a U-phase, W-phase coils working for a W-phase, and V-phase coils working for a V-phase. The U-phase coils, the W-phase coils, and the V-phase coils are arranged alternately in a first circumferential direction of the core. The winding also includes a plurality of power input wires and a plurality of coil-to-coil connecting wires. Each of the power input wires connects between a trailing end of one of the coils for a first phase that is one of the U-phase, the W-phase, and the V-phase and a leading end of one of the coils for a second phase that is one of the U-phase, the W-phase, and the V-phase and different from the first phase. At least one of the power input wires connects ends of the wire together.